Electrostatic discharge device testing system and method

ABSTRACT

There is disclosed an electrostatic discharge (ESD) device tester and a method of operating the tester. In an embodiment, the method comprises operating the tester by uniquely identifying an ESD device to be tested using identification means provided on the tester; taking at least one test measurement of the uniquely identified ESD device using testing means provided on the tester, the testing means being configurable in dependence upon data associated with the uniquely identified ESD device; and storing the at least one test measurement in a storage means provided in the tester. A running average of test measurements for the uniquely identified ESD device may be stored on the tester in order to compare a test measurement against the running average. A test is repeated if a test measurement falls outside of a predetermined range of the running average.

RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.12/355,853 filed on Jan. 19, 2009 now U.S. Pat. No. 7,667,450 which is acontinuation of U.S. patent application Ser. No. 11/445,258 filed onJun. 2, 2006 (now issued as U.S. Pat. No. 7,498,795).

FIELD OF THE INVENTION

The present invention relates generally to the field of electrostaticdischarge (ESD) testing systems and methods.

BACKGROUND

Monitoring and controlling electrostatic discharge or ESD is animportant function in electronics manufacturing, since uncontrolleddischarge may seriously damage ESD-sensitive components. Damage oftenoccurs at a microscopic level, such that the actual damage to acomponent may only be discovered in testing after manufacture, or afterpremature failure experienced by an end user.

Various ESD monitoring devices and ESD protection devices are availableto help manage the risk of ESD during manufacturing and assembly ofsensitive electronic components and devices. For example, an ESDmonitoring device may monitor environmental conditions such astemperature and humidity, and may trigger an alarm if these conditionsfall outside a preferred operating range. An ESD protection device mayinclude, for example, an ESD safe mat for neutralizing static charge onthe table of an electronics assembly station. Another example of an ESDprotection device is an ESD floor mat or flooring that may be used forelectrically grounding an operator that may touch sensitive electroniccomponents and devices during assembly.

In order to ensure that the ESD monitoring and protection devices withinan electronics manufacturing or assembly facility are functioningproperly, it is desirable to test them at regular intervals using ESDdevice testers. A device tester commonly used for this purpose is amegohmmeter that may be used to measure the resistance of an ESDmonitoring or protection device. The resistance measured by themegohmmeter may provide an indication of the potential of an ESDmonitoring or protection device to prevent ESD.

Presently, to test these various ESD monitoring and protection devices,an ESD specialist typically sets the megohmmeter to take a resistancemeasurement for an ESD monitoring or protection device, obtains aresistance measurement, and logs the measurement on a log sheet. This isrepeated for each and every device. While functional, this approach canbecome tedious and cumbersome when many devices must be tested at afacility.

What are needed are systems and methods for more efficiently testing andobtaining measurements for ESD monitoring or protection devices.

BRIEF DESCRIPTION OF THE DRAWINGS

In the figures which illustrate exemplary embodiments of the invention:

FIG. 1A is an illustration of an ESD device tester in accordance with anembodiment;

FIG. 1B is a schematic block diagram of the ESD device tester of FIG.1A;

FIG. 2 is a schematic diagram of an electronics manufacturing/assemblyfacility having a plurality of ESD monitoring and protection devices;

FIG. 3 is a schematic diagram of one of the stations in the facility ofFIG. 2 configured for testing using the system of FIGS. 1A & 1B inaccordance with an embodiment;

FIG. 4 is an illustrative table of test measurement data stored on theESD device tester of FIGS. 1A & 1B;

FIG. 5 is a flowchart of an illustrative method in accordance with anembodiment.

DETAILED DESCRIPTION

As noted above, the present invention relates to electrostatic dischargemonitoring systems and methods.

Shown in FIG. 1A is an illustration of an ESD device tester 100 inaccordance with an embodiment. ESD device tester 100 may be, forexample, a megohmmeter for measuring the resistance of an ESD device.Any suitable megohmmeter may be used. As an example, ESD device tester100 may be a suitably modified version of the 3M™ Model 701 Megohmmetermanufactured by 3M Electronic and Interconnect Solutions Division ofAustin, Tex.

ESD device tester 100 may include a selector switch 102 for selectingone of a plurality of testing modes including, for example, a continuitytest mode, a battery test mode, a 10V surface test mode, and a 100Vsurface test mode. Selector switch 102 may also be used to place ESDdevice tester 100 into an “off” mode. The battery test mode may be usedto test the internal battery powering the ESD device tester 100. Thecontinuity test mode may be used to test the leads 112, 114 to determineif they are functioning properly. Finally, the surface test mode may beused to test the resistance measurement of a surface to be tested. Lightemitting diodes or LEDs 103, 105 may be used to identify the appropriatesetting to be used, as described further below. These test modes will bedescribed in greater detail below.

Still referring to FIG. 1A, ESD device tester 100 may include a testbutton to activate the test function selected using selector 102.Testing may be performed using test leads 112, 114 connected to positiveand negative terminals 106 and 108, respectively. At the opposite end ofthe test leads 112, 114, a pair of contact pads 116, 118 may be providedto make contact with a target surface to be measured. Once the testleads 112, 114 have been connected using contact pads 116, 118 toappropriate locations on a target surface and a test measurement hasbeen taken by actuating test button 104, the result may be read on auser interface/display provided on the megohmmeter. For example, anindicator 122 may be configured to move along one of the scales 120,124, 126 provided. If a surface test is being conducted, the measurementmay be indicated by movement of an indicator 122 along the megohmmeterresistance scale 120. If a continuity test is being conducted, themeasurement indicated by movement of the indicator 122 along thecontinuity scale 124 may be used. Finally, for battery testing, themeasurement may be indicated by movement of the indicator 122 along thebattery scale 126.

Still referring to FIG. 1A, shown is a barcode-reader 130 that may beintegrated into ESD device tester 100 and used to scan a unique barcodelabel provided on each ESD device to be tested using device tester 100.Alternatively, a radio frequency identification (RFID) tag reader may beused to read RFID tags provided in each ESD device to be tested. Theseidentification means will be described in more detail further below.

In addition to the barcode reader 130, ESD device tester 100 may furtherinclude a temperature sensor 140 and a humidity sensor 142. Temperaturesensor 140 and humidity sensor 142 may be used to test environmentalconditions in the immediate vicinity of an ESD device being tested.These sensors 140, 142 may be used independently, or alternatively maybe activated at the same time that barcode reader 130 is activated usingscan button 132, for example.

FIG. 1B shows a schematic block diagram of various components of the ESDdevice tester 100 of FIG. 1A. By way of example, ESD device tester 100may include a megohmmeter sensor 120 suitably configured to performsurface tests as previously described. Megohmmeter sensor 120 may beoperatively connected by a suitable interface controller 122 to dataprocessor 150. Data processor 150 may be operatively connected tostorage 152 and to memory 154. Memory 154 may be a suitable randomaccess memory for temporarily storing data required by data processor150. Storage 152 may be a non-volatile storage that may be used as aninput or produced as an output by data processor 150. Data processor 150may also be operatively connected via an I/O interface 156 to a userinterface 158, a barcode reader subsystem 130, and a wirelesscommunications subsystem 160.

User interface 158 may incorporate a suitable display viewable by an ESDspecialist which may be, for example, an analog dial as shown in FIG.1A. The display may alternatively be a suitable digital graphicaldisplay to provide the ESD specialist with multiple pieces ofinformation.

FIG. 2 is a schematic diagram of an electronics manufacturing/assemblyfacility 200 having a plurality of ESD monitoring and protectiondevices. For example, facility 200 may comprise an electronics assemblyline having a plurality of ESD monitored stations 204 a-204 f. ESDmonitored stations 204 a-204 f may be operatively connected to andcontrolled by an ESD monitoring and process control server 202. CertainESD monitored stations (e.g. 204 b) may be operatively connected to ESDmonitoring and processor control server 202 using a pair of transceivers205 a, 205 b. ESD monitoring and process control server 202 may also beoperatively connected to a communications server 206. Communicationsserver 206 may be operatively connected via a communications network 208to a mobile communications device 210. As will be further explainedbelow, in an embodiment, ESD device tester 100 may be enabled forwireless communications with ESD monitoring and process control server202.

Now referring to FIG. 3, shown is a schematic diagram of one of thestations (e.g. 204 a) in the facility 200 in FIG. 2. As shown, each ESDdevice located at station 204 a is uniquely identified using a barcodelabel. For example, a conveyor 302 which delivers an electronicsassembly to station 204 a may be identified using a barcode label 312 a.Similarly, ESD table 304 may be uniquely identified using barcode label312 b, ESD safe mat 306 may be uniquely identified using barcode label312 c, ESD flooring 308 may be uniquely identified using barcode label312 d, and conveyer 310 to the next station may be uniquely identifiedusing barcode label 312 e.

Still referring to FIG. 3, ESD device tester 100 may be used to testeach device 302, 304, 306, 308, 310 at station 204 a. In accordance withan embodiment, prior to testing each ESD device 302, 304, 306, 308, 310,the barcode reader subsystem 130 of ESD device tester 100 may be used touniquely identify the ESD device. For example, as shown earlier in FIG.1A, scan button 132 may be actuated to initiate a barcode scan usingbarcode reader subsystem 130.

By uniquely identifying the ESD device to be tested, ESD device tester100 can be configured to record a subsequent surface test measurementand associate that surface test measurement to that specific device. Forexample, as shown in FIG. 3, ESD device tester 100 is reading barcode312 a which uniquely identifies conveyor 302. Test leads 112, 114 areshown connected to suitable connection points on conveyor 302. Uponselecting the type of test to be conducted using the ESD device tester100, the measurement taken at conveyor 302 using megohmmeter sensor 120(FIG. 1B) may be processed by data processor 150, and stored innon-volatile storage 152.

In an embodiment, non-volatile storage 152 may store code that whenloaded into data processor 150 configures the data processor 150 touniquely identify the ESD device 302, 304, 306, 308, 310 being tested,and to retrieve from storage (e.g. storage 152) data associated withthat unique ESD device. Storage 152 may store data that specifies one ormore operational settings in ESD device tester 100. For example, if aparticular ESD device requires a certain voltage setting for properoperation (e.g. 10V or 100V surface test), ESD device tester 100 may beconfigured to retrieve the necessary setting. If the voltage setting isto be done automatically, this setting on ESD device tester 100 may beconfigured to be adjustable without manually turning selector 102 (FIG.1). Alternatively, a suitable indicator, such as an LED (e.g. LED 103 or105 of FIG. 1), may be used to indicate the appropriate voltage settingto be used for the particular ESD device 302, 304, 306, 308, 310.

In an embodiment, in addition to providing specific settings to be usedby ESD device tester 100, ESD device tester 100 may also storehistorical information for test measurements of that device. Forexample, as will be explained in more detail below, storage 152 of ESDdevice tester 100 may be used to store the last measured test value forthe ESD device 302, 304, 306, 308, 310. In an embodiment, ESD devicetester 100 may also be used to identify any significant discrepancy froma previously stored test measurement for a particular ESD device,indicating a possible problem with the ESD device 302, 304, 306, 308,310, the ESD device tester 100, or perhaps that the test was notproperly done. In this manner, the ESD specialist may be alertedimmediately so that another confirmation test may be taken using the ESDdevice tester 100.

FIG. 4 is an illustrative table of sample test measurement data 400stored on the ESD device tester of FIG. 1 (e.g. in storage 152). Asshown, a first column 410 may include a plurality of unique barcodevalues that uniquely identify each of the ESD devices 302-310 listed incolumn 420. A column 430 may specify the appropriate voltage setting foreach ESD device in column 420. Another column 440 may store the lastrecorded surface test measurement for each ESD device in column 420.Another column 450 may store the current surface test measurement foreach ESD device in column 420.

In an embodiment, instead of or in addition to a last recorded surfacetest measurement for each ESD device in column 420, a running average ofsurface test measurements for each ESD device may be stored. This mayallow the ESD specialist to compare the current test measurement for aparticular ESD device to an average test measurement taken over a longerperiod of time (e.g. an average of the last ten measurements).

The data stored in the table in FIG. 4 may allow an ESD specialist totest ESD devices 302-310 more efficiently by uniquely identifying theESD device 302, 304, 306, 308, 310 to be tested, retrieving and applyingany settings for the ESD device tester 100 specific to that ESD device302, 304, 306, 308, 310, and optionally retrieving a history or averageof previous test measurements to validate the current test measurementsthat are taken.

In another embodiment, temperature sensor 140 and humidity sensor 142may be used to test environmental conditions in the immediate vicinityof an ESD device being tested and these temperature and humiditymeasurements may be stored together with the surface resistancemeasurements to help interpret any variations in surface resistance testmeasurements.

In a further embodiment, in addition to retrieving data and configuringthe ESD device tester 100 in some manner (e.g. applying specific testsettings for the device), user instructions for correct placement oftest leads 112, 114 may also be retrieved depending on the type of ESDdevice in column 420. For example, based on the unique identificationprovided by the barcode value in column 410, appropriate textinstructions may be provided via a display in user interface 158. Thetext instructions may, for example, guide a user to place test leads112, 114 on marked test points provided on a type of ESD device.Alternatively, a graphic of the particular ESD device may be provided tovisually identify the location of the test contact points to be used forthe particular type of ESD device. Rather than being individual to eachESD device, the text instructions or graphic may be stored for a finitenumber (e.g. 6 to 12) of different kinds of ESD devices that may betested using ESD device tester 100.

In an embodiment, the data stored in the table in FIG. 4 may be uploadedfrom ESD device tester 100 to a host server, such as the ESD monitoringand process control server 202 of FIG. 1. This may be done either byconnecting ESD device tester 100 directly to server 202 via a suitableconnector (e.g. via serial, parallel, universal serial bus (USB), orFireWire), or if ESD device tester 100 is also configured with awireless communications subsystem 160, then wirelessly viacommunications network 208 and communications server 206 (FIG. 2).

FIG. 5 is a flowchart of an illustrative method 500 in accordance withan embodiment corresponding to the above description. At block 502, anESD specialist may uniquely identify an ESD device to be tested (e.g.using a barcode reader subsystem 130 integrated into ESD device tester100). Upon unique identification of the ESD device to be tested, method500 proceeds to block 504, where data specific to the ESD device to betested may be retrieved (e.g. from non-volatile storage 152). Uponretrieval of the data, method 500 proceeds to block 506 where the ESDdevice tester 100 is configured based on the retrieved data. This mayinclude, for example, configuring ESD device tester 100 to be ready toaccept a test measurement value.

As previously described, the retrieved data may also include aparticular setting for the ESD device tester 100 specific to that ESDdevice. The retrieved data may also include historic measurement datafor the ESD device which may include, for example, the last recordedtest measurement, or some average of a plurality of previously recordedtest measurements.

At block 508, as a test measurement is taken, if the retrieved dataincludes instructions on how the testing should be performed (e.g. byproviding text instructions or a graphic illustration on locating thecorrect contact points on a particular type of ESD device for testing)the data is displayed to the user so that the testing procedure willremain consistent from one test to the next even if performed bydifferent individuals. This may help to ensure that any variationsbetween successive test measurements are more meaningful.

Method 500 then proceeds to block 510, where one or more testmeasurements are taken (e.g. by actuating test button 104) and stored.For example, a test measurement may be taken for a surface test, as wellas one or more of temperature and humidity.

If the retrieved data also includes historical test measurement data,method 500 may proceed to decision block 512 to determine if themeasurement is unexpected (i.e. outside of a predetermined acceptablerange of variation). If no, method 500 proceeds directly to decision 514where, if there are more ESD devices to be tested, method 500 may returnto block 502 to uniquely identify the next ESD device. If yes, method500 may optionally proceed to block 513 to take another measurement toverify the test before proceeding to decision block 514.

At decision block 514, if there are no more ESD devices to be tested,method 500 may proceed to block 516 where the test measurement datastored on ESD device tester 100 may be uploaded to a host server (e.g.ESD monitoring and process control server 202 of FIG. 2) for processing.The processing may include, for example, updating a database ofhistorical test measurement data for every ESD device tested. Thehistorical test measurement data may be analyzed using variousstatistical methods.

In an embodiment, the result of any processing done on the host servermay be downloaded back to the ESD device tester 100 in order to providethe ESD device specific data that may be retrieved during the next ESDtesting at the electronics facility. Method 500 then ends.

It will be appreciated that the systems and methods as described abovemay assist an ESD specialist in conducting testing of numerous ESDdevices at a facility in a more efficient manner.

Thus, in an aspect, there is provided a method of operating a portableelectrostatic discharge (ESD) device tester, comprising: (i) uniquelyidentifying an ESD device to be tested using identification meansprovided on the tester; (ii) taking at least one test measurement of theuniquely identified ESD device using testing means provided on thetester, the testing means being configurable in dependence upon dataassociated with the uniquely identified ESD device; and (iii) storingthe at least one test measurement in a storage means provided in thetester.

In an embodiment, the method further comprises calculating a runningaverage of test measurements for the uniquely identified ESD device.

In another embodiment, the method further comprises comparing the atleast one test measurement for the uniquely identified ESD device to thecalculated running average of test measurements.

In another embodiment, the method further comprises repeating a testmeasurement if the at least one test measurement is not within apredetermined range of the running average of test measurements for theuniquely identified ESD device.

In another embodiment, the method further comprises transferring the atleast one test measurement to a host server for processing.

In another embodiment, the testing means is a megohmmeter, the testmeasurement is a surface resistance test, and the method furthercomprises configuring the voltage to be used for the surface resistancetest in dependence upon the uniquely identified ESD device.

In another embodiment, the identification means is one of a barcodereader and a radio frequency identification (RFID) tag reader, and themethod further comprises reading a barcode or an RFID tag uniquelyidentifying an ESD device.

In another aspect of the invention, there is provided a portableelectrostatic discharge (ESD) device tester, comprising: identificationmeans for uniquely identifying an ESD device to be tested; testing meansfor taking at least one test measurement of the uniquely identified ESDdevice, the testing means being configurable in dependence upon dataassociated with the uniquely identified ESD device; and storage meansfor storing the at least one test measurement.

In an embodiment, the system further comprises means for calculating arunning average of test measurements for the uniquely identified ESDdevice.

In another embodiment, the system further comprises means for comparingthe at least one test measurement for the uniquely identified ESD deviceto the calculated running average of test measurements.

In another embodiment, the system further comprises means for repeatinga test measurement if the at least one test measurement is not within apredetermined range of the running average of test measurements for theuniquely identified ESD device.

In another embodiment, the system further comprises means fortransferring the at least one test measurement to a host server forprocessing.

In another embodiment, the testing means is a megohmmeter, the testmeasurement is a surface resistance test, and the system furthercomprises means for configuring the voltage to be used for the surfaceresistance test in dependence upon the uniquely identified ESD device.

In another embodiment, the system further comprises means is one of abarcode reader and a radio frequency identification (RFID) tag reader.

In another aspect of the invention, there is provided a computerreadable medium storing computer code that when loaded into a portableelectrostatic discharge (ESD) device tester adapts the tester to obtaintest measurements, the computer readable medium including: code foruniquely identifying an ESD device to be tested using identificationmeans provided on the tester; code for taking at least one testmeasurement of the uniquely identified ESD device using testing meansprovided on the tester, the testing means being configurable independence upon data associated with the uniquely identified ESD device;and code for storing the at least one test measurement in a storagemeans provided in the tester.

In an embodiment, the computer readable medium further includes code forcalculating a running average of test measurements for the uniquelyidentified ESD device.

In another embodiment, the computer readable medium further includescode for comparing the at least one test measurement for the uniquelyidentified ESD device to the calculated running average of testmeasurements.

In another embodiment, the computer readable medium further includescode for repeating a test measurement if the at least one testmeasurement is not within a predetermined range of the running averageof test measurements for the uniquely identified ESD device.

In another embodiment, the computer readable medium further includescode for transferring the at least one test measurement to a host serverfor processing.

In another embodiment, the testing means is a megohmmeter, the testmeasurement is a surface resistance test, and the computer readablemedium further includes code for configuring the voltage to be used forthe surface resistance test in dependence upon the uniquely identifiedESD device.

While illustrative embodiments have been described above, it will beappreciated that various changes and modifications may be made. Moregenerally, the scope of the invention is defined by the followingclaims.

1. A method of operating a portable electrostatic discharge (ESD) devicetester to test a plurality of ESD devices at ESD monitored stationswithin an electronics manufacturing or assembly facility, comprising:uniquely identifying an ESD device used in an electronics manufacturingprocess and to be tested, using identification means provided on theportable ESD device tester to scan a unique label on the ESD device;configuring testing means provided on the portable ESD device tester independence upon the identity of the uniquely identified ESD device;taking at least one test measurement of the uniquely identified ESDdevice using the testing means provided on the portable ESD devicetester; and storing the at least one test measurement in a storage meansprovided in the portable ESD device tester; wirelessly uploading the atleast one test measurement to a host server.
 2. The method of claim 1,further comprising updating on the host server a database of historicaltest measurement data for the uniquely identified ESD device.
 3. Themethod of claim 2, further comprising comparing the at least one testmeasurement for the uniquely identified ESD device to the database ofhistorical test measurement data for the uniquely identified ESD deviceand analyzing the at least one test measurement data using a statisticalmethod.
 4. The method of claim 3, further comprising determining usingthe statistical method if the at least one test measurement is notwithin a predetermined range of the running average of test measurementsfor the uniquely identified ESD device.
 5. The method of claim 4,further comprising downloading the result of any processing done on thehost server back to the portable ESD device tester to provide analyzeddata for the uniquely identified ESD device that may be retrieved duringthe next ESD testing of the uniquely identified ESD device.
 6. Themethod of claim 1 wherein the testing means is a megohmmeter, and thetest measurement is a surface resistance test.
 7. The method of claim 1,wherein the identification means is one of a barcode reader and a radiofrequency identification (RFID) tag reader, and the method comprisesreading a barcode or an RFID tag uniquely identifying an ESD device. 8.A portable electrostatic discharge (ESD) device testing system to test aplurality of ESD devices at ESD monitored stations within an electronicsmanufacturing or assembly facility, comprising: identification means foruniquely identifying an ESD device, based on a unique label on the ESDdevice, at one of the ESD monitored stations within the electronicsmanufacturing or assembling facility and to be tested; first testingmeans, on the portable ESD device, for taking at least one testmeasurement of the uniquely identified ESD device; second testing means,on the portable ESD device, for taking a measurement of at least oneenvironmental condition near the vicinity of the uniquely identified ESDdevice; and configuration means, on the portable ESD device, forconfiguring the testing means in dependence upon the identity of theuniquely identified ESD device; storage means, on the portable ESDdevice, for storing the at least one test measurement; and wirelesscommunications means, on the portable ESD device, for wirelesslyuploading the at least one test measurement to a host server.
 9. Thesystem of claim 8 further comprising means for updating on the hostserver a database of historical test measurement data for the uniquelyidentified ESD device.
 10. The system of claim 9, further comprising:means for comparing the at least one test measurement for the uniquelyidentified ESD device to the database of historical test measurementdata for the uniquely identified ESD device; and means for analyzing theat least one test measurement data using a statistical method.
 11. Thesystem of claim 10, further comprising means for determining using thestatistical method if the at least one test measurement is not within apredetermined range of the running average of test measurements for theuniquely identified ESD device.
 12. The system of claim 11, furthercomprising means for downloading the result of any processing done onthe host server back to the portable ESD device tester to provideanalyzed data for the uniquely identified ESD device that may beretrieved during the next ESD testing of the uniquely identified ESDdevice.
 13. The system of claim 8 wherein the testing means is amegohmmeter, the test measurement is a surface resistance test.
 14. Thesystem of claim 8, wherein the identification means is one of a barcodereader and a radio frequency identification (RFID) tag reader.